Robot And Method For Controlling A Robot

ABSTRACT

The invention relates to a robot (R,  70 ) and to a method for controlling a robot (R,  70 ). The distance (d) between an object (P) and the robot (R,  70 ) and/or the derivative thereof or a first motion of the object (P) is detected by means of a non-contact distance sensor ( 20, 20′ ) arranged in or on a robot arm (M) of the robot (R,  70 ) and/or on or in an end effector ( 19′ ) fastened on the robot arm (M). The robot arm (M) is moved based on the first motion detected by means of the distance sensor ( 20, 20′ ), a target force or a target torque to be applied by the robot (R) is determined based on the distance (d) detected between the object (P) and the robot (R), and/or a function of the robot (R) or a parameterization of a function of the robot (R) is triggered based on the first motion detected and/or a target distance between the object (P) and the robot (R) and/or the derivative thereof detected by means of the distance sensor ( 20, 20′ ).

The invention relates to a robot, and to a method for controlling a robot.

Robots are manipulating machines, which are equipped with useful tools for automatic handling of objects, and are programmable in a plurality of motion axes, in particular with regard to orientation, position and process sequence. Robots have essentially a robotic arm with a plurality of axes and levers, which are moved by drives. The drives are for example electric drives.

The robot or its robot arm can also be moved manually, for example by means of a hand-held device or by guiding it manually. In particular when moving the robot by guiding it manually, in the course of which a person for example pushes or pulls on the robot arm, the danger exists that by touching the robot arm the person guiding the robot will be contaminated by the robot. This is particularly disadvantageous when the robot is used in the medical environment.

The object of the present invention is to create prerequisites for contact-free control of a robot.

The object of the invention is fulfilled by a method for controlling a robot, having the following procedural steps:

-   -   detecting a first movement of an object by means of a         non-contact distance sensor situated in or on a robot arm of a         robot and/or on or in an end effector attached to the robot arm,         or detecting the distance between the object and the robot or         the latter's derivative by means of the distance sensor, and     -   moving the robot arm on the basis of the first movement detected         by means of the distance sensor, ascertaining a target force or         target torque to be produced by the robot and/or its derivatives         on the basis of the detected distance between the object and the         robot and/or its derivative, or triggering a function of the         robot and/or a parameterizing of a function of the robot on the         basis of the detected first movement and/or on the basis of a         target distance between the object and the robot detected by         means of the distance sensor.

The target distance may be in particular a minimum distance.

The object of the invention is also fulfilled by a robot having

-   -   a robot arm with a plurality of axes, an attaching device for         attaching an end effector, and drives to move the axes,     -   at least one non-contact distance sensor situated on or in the         robot arm, and     -   a control device coupled with the drives and the distance         sensor, which is set up         -   to move the robot arm by means of the drives on the basis of             a first movement of an object detected by means of the             distance sensor,         -   to ascertain a target force or target torque to be produced             by the robot on the basis of a distance between the object             and the robot and/or the latter's derivative detected by             means of the distance sensor, and/or         -   to trigger a function of the robot and/or to parameterize a             function of the robot on the basis of the first movement             detected by means of the distance sensor and/or to trigger a             function of the robot and/or to parameterize a function of             the robot on the basis of a detected target distance and/or             its derivative.

Alternatively, the distance sensor may also be situated in or on the end effector and coupled with the control device of the robot according to the invention.

Accordingly, it is possible to carry out the method according to the invention using the robots according to the invention.

According to the invention, the at least one non-contact distance sensor is accordingly situated in or on the robot arm, for example on its structure, or in or on the end effector. Non-contact distance sensors as such are generally known, and generate a signal assigned to the distance between an object and the non-contact distance sensor, in particular an electrical signal. It is then also possible from this signal to ascertain the first movement of the object and/or the velocity of the object relative to the robot, on the basis of a derivative of the signal assigned to the distance. The object may be in particular a person, for example operating the robot according to the invention, so that this person is enabled to control the robot without contact.

Non-contact distance sensors are for example capacitive distance sensors, or are based on other physical laws.

On the basis of the distance between the object and the robot ascertained or its derivative by means of the non-contact distance sensor, or the first movement of the object ascertained by means of the distance sensor, it is provided for example according to the invention to initiate for example the function of the robot and/or the parameterizing of the function of the robot. The derivative of the distance between the object and the robot is the speed between the object and the robot. A function of the robot may be for example activating and/or deactivating an end effector situated on the attaching device. That enables a person operating the robot according to the invention to control the function of the end effector, which is for example a tool guided or moved with the robot according to the invention, generally without contact, in particular to switch it on and off without contact, without using a control panel for example. This not only results in the person not needing to touch the robot according to the invention to activate the end effector, but can also result in easier operation of the robot according to the invention.

On the basis of the distance between the object and the robot or its derivative ascertained by means of the non-contact sensor, according to an alternative embodiment of the robot according to the invention or of the method according to the invention the control device in particular ascertains the target force or target torque to be produced. Because of the use of the non-contact distance sensor, a person operating the robot according to the invention can be enabled to set the target force or target torque to be produced by the robot according to the invention in a relatively simple way, not only without contact but also relatively simply, by intuition.

According to one variant of the method according to the invention, or according to one variant of the robot according to the invention, the target force or target torque to be produced is a target force or a target torque to be produced by an end effector situated on the robot arm. The control device of the robot according to the invention can then be set up to activate the axes via the drives so that the end effector situated on the attaching device produces the target force or the target torque.

According to one variant of the method according to the invention, the robot arm is moved in such a way that an attaching device of the robot arm or the tool center point of an end effector situated on the robot arm executes a second movement corresponding to the first movement of the object, on the basis of the detected first movement. The control device of the robot according to the invention can be set up for that purpose so that it moves the axes by means of the drives in such a way that the attaching device or the tool center point of the end effector executes a second movement corresponding to the first movement of the object, on the basis of the detected first movement. On the basis of this embodiment, the person operating the robot according to the invention is enabled to guide the robot without contact, by executing the first movement, on the basis of which the robot arm moves automatically in such a way that it moves the attaching device or the tool center point in accordance with the movement of the person. On the basis of this embodiment of the robot according to the invention, it is possible for a person, as an object, to change the position or location of the robot according to the invention by approaching it purposively, without touching the robot. Thus prerequisites are created for guiding the robot according to the invention without touching it, whereby potential contamination of the person guiding the robot according to the invention by touching the robot can be avoided.

According to another embodiment of the method according to the invention, the robot arm is moved on the basis of the detected first movement, in order to prevent a collision of the object with the robot arm and at the same time to keep the position of an attaching device of the robot arm or of the tool center point of an end effector situated on the robot arm constant. The control device of the robot according to the invention can accordingly be set up to move the axes via the drives on the basis of the detected first movement, in order to prevent collision of the object with the robot arm, but to keep the position of the attaching device or of the tool center point of the end effector constant. This is possible for example when the robot according to the invention is what is known as a redundant robot, so that it can execute a movement in its zero space. Zero space designates the joint angle space of the redundant robot, in which it is possible to reconfigure the robot joints in such a way that the situation (position and orientation) of the end effector of the robot in space remains unchanged. This embodiment of the robot according to the invention can be used for example in robot-supported surgery, in order for example to enable a person as object, for example a doctor, to have access to the operation zone without removing the robot according to the invention or interrupting an intervention being carried out with the robot according to the invention.

Examples of exemplary embodiments of the invention are depicted in the accompanying schematic drawing. The figures show the following:

FIG. 1 a robot with non-contact distance sensors,

FIGS. 2, 3 an acquisition field of the non-contact distance sensors,

FIGS. 4-6 flow charts to illustrate the operation of the robot of FIG. 1,

FIG. 7 another robot,

FIG. 8 a flow chart to illustrate the operation of the robot of FIG. 7, and

FIG. 9 an end effector for a robot.

FIG. 1 shows a robot R with a robot arm M. Robot arm M represents essentially the movable part of robot R, and includes a plurality of axes 1-6, a plurality of levers 7-10 and a flange 18, to which an end effector 19, which is for example a medical instrument, in particular a surgical instrument, is attached.

Each of the axes 1-6 is moved with a drive, for example an electric drive 11-16, which are electrically connected in a non-depicted manner to a control computer 17 of robot R, so that control computer 17 or a computer program running on control computer 17 is able to activate electric drives 11-16 in such a way that the position or location of flange 18 of robot R or the tool center point TCP of robot R can be oriented essentially freely in space. Electric drives 11-16 of robot R each include for example an electric motor and possibly power electronics that activate the motors.

In the case of the present exemplary embodiment, robot R also has non-contact distance sensors 20 that are connected to control computer 17 in a non-depicted manner, which are situated in or on robot arm M, in particular integrated into the structure of robot arm M, or are set into an outer skin that encloses robot arm M, for example at individual spots or over a wide area. The non-contact distance sensors 20 are for example, as is the case in the present exemplary embodiment, capacitive distance sensors 20, which as such are known to a person skilled in the art. The distance sensors 20 are set up to ascertain a distance d to an object, for example to a person P.

As just mentioned, in the case of the present exemplary embodiment the non-contact distance sensors 20 are capacitive distance sensors 20, which together produce an acquisition field 21 which at least partially encloses robot arm M and is depicted in FIGS. 2 and 3. FIG. 2 shows robot R with acquisition field 21 in a side view, and FIG. 3 shows robot R with acquisition field 21 in a top view.

If person P for example approaches this acquisition field 21, then distance sensors 20 generate a signal corresponding to the distance d between person P and robot R, which is transmitted to control computer 17 for further processing. In the case of the present exemplary embodiment, control computer 17 or a computer program running on control computer 17 controls the movement of robot R on the basis of this signal. This is summarized by means of a flow chart depicted in FIG. 4.

If person P approaches robot R, distance sensors 20 detect the distance d between robot R and person P. The signals assigned to distance d and coming from distance sensors 20 are transmitted to control computer 17, which recognizes a movement of person P on the basis of the signals, in particular on the basis of a detected change in the distance d between person P and robot R, step S1 of the flow chart in FIG. 4.

On the basis of the detected movement of person P, in the case of the present exemplary embodiment control computer 17 calculates a movement corresponding to the movement of person P, which is to be executed by effector 19 or its tool center point TCP, step S2 of the flow chart.

On the basis of the calculated movement that effector 19 or the tool center point TCP is to execute, control computer 17 activates drives 11-16 in such a way that effector 19 or tool center point TCP executes this movement without person P touching robot R, step S3 of the flow chart in FIG. 4.

In another exemplary embodiment, robot R or control compute 17 is configured so that a target force or target torque to be produced by robot R, and/or their respective derivatives, are calculated by means of the distance sensors 20. This is summarized by means of a flow chart depicted in FIG. 5.

If person P approaches robot R, distance sensors 20 detect the distance d between robot R and person P. The signals assigned to distance d and coming from distance sensors 20 are transmitted to control computer, step S1′ of the flow chart in FIG. 5.

On the basis of the distance d, in the case of the present exemplary embodiment control computer 17 calculates a target force or target torque corresponding to the distance d, and/or their respective derivatives, which the end effector 19 situated on robot arm M is to produce, step S2′ of the flow chart in FIG. 5.

Control computer 17 then activates drives 11-16 in such a way that end effector 19 applies the calculated target force to an object not depicted in further detail in the figures, step S3′ of the flow chart in FIG. 5. Thus it is possible to set the force to be produced by end effector 19 and/or its derivative without contact, via the distance d to robot R. Alternatively, it is also possible to set a torque to be produced by end effector 19 and its derivative, instead of a force, via the distance d between person P and robot R.

In another exemplary embodiment, robot R or control computer 17 is configured so that a function of robot R and/or a parameterizing of a function of robot R is carried out automatically if the distance d between person P and robot R falls below a minimum distance or exceeds a maximum distance. This is summarized by means of a flow chart depicted in FIG. 6.

If person P approaches robot R so that distance d falls below the minimum distance, then this is detected by the distance sensors 20 or by control computer 17, step A1 of the flow chart in FIG. 6.

In the case of the present exemplary embodiment, control computer 17 then activates end effector 19, step A2 of the flow chart in FIG. 6.

FIG. 7 shows another robot 70, with a robot arm M having a plurality of axes. Robot 70 in the case of the present exemplary embodiment is a redundant robot R, for which reason it is able to execute a movement in its zero space. Zero space designates the joint angle space of redundant robot 70, in which it is possible to reconfigure robot joints 71-77 in such a way that the situation (position and orientation) of end effector 19 in space remains unchanged. This embodiment of robot 70 can be used for example in robot-supported surgery.

In the case of the present exemplary embodiment, person P can operate robot 70 as follows, which is illustrated by means of a flow chart depicted in FIG. 8.

If person P approaches robot 70, this is detected by means of the distance sensors 20, step Al of the flow chart in FIG. 8, for example by deriving the signal assigned to the distance.

To prevent a collision of person P with the relevant part of robot 70, control computer 17 activates drives 81-87 of robot 70 on the basis of the detected approach of person P to robot 70, in such a way that on the one hand the location of end effector 19 in space remains unchanged, the relevant lever or the relevant joint 71-77 with which person P potentially will collide yields to the approach of person P, step A2′ of the flow chart in FIG. 8.

The robots R, 70 described above include the distance sensors 20, which are situated in or on the corresponding robot arms M. But it is also possible, additionally or alternatively, to situate the distance sensors 20 on the end effector. FIG. 9 shows such an end effector 19′, in which or on which distance sensors 20′ are situated. 

1. A method for controlling a robot, having the following procedural steps: detecting a first movement of an object (P) by means of a non-contact distance sensor (20, 20′) attached in or on a robot arm (M) of a robot (R, 70) and/or in an end effector (19′) attached to the robot arm (M), or detecting the distance (d) between the object (P) and the robot (R, 70) by means of the distance sensor (20, 20′), and moving the robot arm (M) on the basis of the first movement detected by means of the distance sensor (20, 20′), ascertaining a target force or target torque to be produced by the robot (R) on the basis of the detected distance (d) and/or on the basis of a derivative of the detected distance (d) between the object (P) and the robot (R), or triggering a function of the robot (R) and/or a parameterizing of a function of the robot (R) on the basis of the first movement and/or on the basis of a target distance between the object (P) and the robot (R) and/or its derivative detected by means of the distance sensor (20, 20′).
 2. The method according to claim 1, having movement of the robot arm (M) in such a way that an attaching device (18) of the robot arm (M) or the tool center point (TCP) of an end effector (19, 19′) situated on the robot arm (M) executes a second movement corresponding to the first movement of the object (P) on the basis of the detected first movement.
 3. The method according to claim 1 or 2, having, on the basis of the detected first movement, movement of the robot arm (M) such as to prevent a collision of the object (P) with the robot arm (M), and at the same time to keep the location of an attaching device (18) of the robot arm (M) or of the tool center point (TCP) of an end effector (19, 19′) situated on the robot arm (M) constant.
 4. The method according to one of claims 1 through 3, having activation of the robot (R) such that an end effector (19, 19′) situated on the robot arm (M) produces the ascertained target force and/or the ascertained target torque.
 5. The method according to one of claims 1 through 4, wherein the function of the robot (R) is an activation and/or deactivation of an end effector (19, 19′) situated on the attaching device (18), and/or the distance sensor is a capacitive distance sensor (20, 20′).
 6. A robot, having a robot arm (M) with a plurality of axes (1-6, 71-77), an attaching device (18) for attaching an end effector (19), and drives (11-16, 81-87) for moving the axes (1-6), at least one non-contact distance sensor (20) situated on or in the robot arm (M), and a control device (17) coupled with the drives (11-16, 81-87) and the distance sensor (20), which is set up to move the robot arm (M) by means of the drives (11-16, 81-87) on the basis of a first movement of an object (P) detected by means of the distance sensor (20), to ascertain a target force or target torque to be produced by the robot (R) on the basis of a distance (d) between the object (P) and the robot (R) and/or a derivative of the distance (d) detected by means of the distance sensor, and/or to trigger a function of the robot (R) and/or to parameterize a function of the robot (R) on the basis of the first movement detected by means of the distance sensor (20) and/or on the basis of a detected target distance and/or its derivative.
 7. A robot, having a robot arm (M) with a plurality of axes (1-6, 71-77), an attaching device (18) for attaching an end effector (19′), and drives (11-16, 81-87) for moving the axes (1-6), and a control device (17) coupled with the drives (11-16, 81-87) and with the non-contact distance sensor (20′) situated on or in the end effector (19′), which is set up to move the robot arm (M) by means of the drives (11-16, 81-87) on the basis of a first movement of an object (P) detected by means of the distance sensor (20′), to ascertain a target force or target torque to be produced by the robot (R) on the basis of a distance (d) between the object (P) and the robot (R) and/or its derivative detected by means of the distance sensor (20′), and/or to trigger a function of the robot (R) and/or to parameterize a function of the robot (R) on the basis of the first movement detected by means of the distance sensor (20′) and/or on the basis of a detected target distance and/or its derivative.
 8. The robot according to claim 6 or 7, whose control device (17) is set up to move the axes (1-6, 71-77) by means of the drives (11-16, 81-87) in such a way that the attaching device (18) or the tool center point (TCP) of the end effector (19, 19′) executes a second movement corresponding to the first movement of the object (P) on the basis of the detected first movement.
 9. The robot according to claim 6 or 7, whose control device (17) is set up to move the axes (1-6, 71-77) via the drives (11-16, 81-87) on the basis of the detected first movement in order to prevent a collision of the object (P) with the robot arm (M), but to keep the location of the attaching device (18) or of the tool center point (TCP) of the end effector (19, 19′) constant.
 10. The robot according to one of claims 6 through 9, wherein the function of the robot (R) is an activation and/or deactivation of an end effector (19, 19′) situated on the attaching device (18), the control device (17) activates the axes (1-6, 71-77) via the drives (11-16, 81-87) in such a way that the end effector (19, 19′) situated on the attaching device produces the target force or the target torque, and/or the distance sensor is a capacitive distance sensor (20, 20′). 